1 Purpose and Scope - Viasat

Viasat, Inc. Process Area: Document Number: Revision: Quality PR001336 002

Name of Document: Process Category: Page: Viasat, Inc. Cosmetic Inspection Criteria Quality 1 of 23

1 Purpose and Scope The purpose of this standard is to define and establish acceptance and rejection criteria for surface finish for incoming and outgoing inspections applicable at Customer, approved Supplier or Subcontractor and Viasat. The company uses similar inspection criteria as today’s technology and market leader. Viasat can meet any surface finish on request; our finishing standard is common industrial finish described in Surface Categories Section.

Each finishing class stands for special manufacturing and handling processes, which are proportional to the related costs. Every customer has to decide if a special cosmetic finish is a requirement or “nice to have”. Manufacturing processes of bare material (e.g. cold rolled steel, pre galvanized steel, extruded parts) as well from machining processes (e.g. punching, forming, and welding) may leave visible marks at the finished products, which are not avoidable. Anodized material is more scratch resistant than Alodine material.

This standard applies to Surface Finishes such as Paint, Chemical Conversion Coating (Alodine, Anodize), Plating, Molding and silk-screening. Inspection Purpose The inspection purpose is to determine any conditions for which the part or system will be rejected. The intent of inspection is To ship a part or system that meets the finish standard of this specification. It is NOT the intent of inspection to find all imperfections on a part or system.

2 Terms and Defect Definitions Accept per approved engineering drawing Some cosmetic imperfections are not avoidable in certain process and design circumstances. Approved engineering documents will point this out.

Abrasion Surface imperfection that doesn’t remove or displace material appears as a scuff or changes to the surface finish.

Bare Metal A metal surface that has an intact protective coating but no cosmetic finish.

Base Metal A bare metal surface on which the protective coating has been compromised. Bleed Out A Substance that runs out of seams. Color can vary from brown, dark brown to gray white at plating.

Name of Document: Document Number: Revision Page: Viasat, Inc. Cosmetic Inspection Criteria PR001336 002 2 of 23

Bleeding Rough and not densely packed dull gray lines at plated material. Blister A bubbling in the surface of the finish. Non-adhesion or lack of proper sticking of the coating to the surface caused by trapped air, gas or moisture.

Blush Discoloration or change in gloss. Burns Brown marks or streaks on a surface of the part caused by trapped gases burning the surface of the plastic during molding operation.

Bubble A bubbling in the surface of the finish. Non-adhesion or lack of proper sticking of the coating to the surface caused by trapped air, gas or moisture.

Bump Protrusions caused by trapped air / gas or moisture usually seen in finished parts.

Burnish Marks Marks or lines that cannot be felt usually caused by tooling dies most common on flattened cold rolled material e.g. Steel or aluminum sheets


Burrs Sharp edges around part features caused by manufacturing process like punching, shearing, milling or drilling.

Caution: Sheet metal edges that are compliant to UL 1439 can still cut through protective gloves and/or human hands.

Chipping Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light rubbing.

Cloudiness A haziness or lack of clarity in otherwise transparent part.


Contamination Rough and not densely packed dull gray lines at plated material. Colored specks of foreign material embedded in or on the surface part.

Corrosion Areas of corrosion on any metal surfaces.

Caution: Small areas of rust are acceptable where plating is removed by a standard manufacturing or welding process, e.g. sheared (cut) edges.

Cracking Crackled appearance due to poor adhesion usually from surface contamination before plating.

Hairline cracks of anodized material caused by bending, high temperature curing after silk screening of the aluminum or tool mark hair cracks on the opposite site of the aluminum.

Fine damages which may extend in a pattern on or beneath the surface or through a layer of material.


Crazing A fine mesh of minute cracks on the surface of some plastics due mainly to the effects of UV light.

Delaminating Separation, peeling of thin layer of material

Dent A surface depression caused by an impact.

Caution: Tooling marks are not dents. Die marks Marks made on the metal’s surface when it is formed, usually consist of long straight lines.


Ding Roughly funnel shaped dent caused by an impact.

Dirt Any particle of foreign material.


Discoloration Any change from the original color or shade in the finish.

Distortion A deformation of a diecasted part


Dust Small particles.

Fill In An excess of ink that alters the form of a screened feature not affecting legibility. Fingerprints An impression left on the surface due to operator handling.

Finish An area of smoother finish of molded plastic parts.


Flaking Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light rubbing.

Flash Thin, excess material usually around the area of the mold parting line or internal shutoff areas.

Flow Marks Waviness of edge or excess linear surface texture of silk-screened areas.

Fracture Material splitting usually on the outside bend radius.

Gates Point at which plastic is injected in cavity, usually on parting line.

Gloss A uniform appearance of a painted or molded area. E.g. Shiny, matt

Glossiness An area of either excessive or deficient gloss.

Gouge A groove or scratch that extends through the finish and into the metal caused by a sharp object. A depth is measurable.


Grease Any lubricant transferred to the part’s surface, shiny or glossy patches on the surface of the part.

Haze Cloudiness on an otherwise transparent part.

Inconsistency Variation of gloss, thickness of line or surface texture.

Inclusions Small craters on surface caused by dust or dirt.

Lint Any unintended foreign substance in the coating or on the surface.

Marbling Colored streaks on a surface caused by improper mixing of molten plastic.

Marks Pits, sanding, or other marks on base material that remains visible after coating.

Matt Finish A less glossy finish of a surface area.

Metal Fuzz Fine grit metal shavings that are clumped together may also be magnetic.


Nicks Like gouges but short of length caused by impact.

Non-adhesion Lack of proper sticking of the coating or a glued material to the surface.

Non-uniform Coverage Areas that have an insufficient or excessive coating.

Oils Oily material on the surface due to materials used in manufacturing processes. Oily looking spots caused by Loctite locking feature.

Orange Peel Paint defect, rippled or mottled appearance viewable as concentric lines caused by under pressurizing not dried paint surfaces.

Orange Skin Paint defect, rippled or mottled appearance.

Oxidation Has a rough feel of appearance. Dull gray, dark gray, black, brown, dark cinnamon or possibly white colored substance.

Peeling Areas in which the adhesion between the paint and the surface is poor, causing the paint to come off with light rubbing.


Pitting Small craters on surface.

Punch mark Mark on the surface of a material due to punch process.

Runs Drips, bleeding, visible lines or raised areas of excessive paint or chemical coating similar to non-uniform coverage.


Rust Areas of corrosion on any metal surfaces .

Caution: Small areas of rust are acceptable where plating is removed by a standard manufacturing or welding process, e.g. sheared (cut) edges.

Scratch A shallow groove that can be seen but not felt.

Scuff marks A series of very light, concentrated scratches that can be seen but not felt.

Short-Shot Incomplete molded feature.


Sink Depression or dimple caused by non-uniform material shrinkage. Slug Mark A surface deformity caused by the punching process.

Smearing The presence of ink on areas not called out in the master artwork.


Smudge Any dirt particle of foreign material.

Specks Small particles.


Spot Weld Mark Dish shaped surface caused by spot welding process.


Tooling Marks Very shallow lines which are parallel to bends in part. Unwanted impact of a tool during punch process.

Caution: Some tooling marks are not avoidable in some process steps. E.g. punching, forming, and bending.

Texture An area of rougher finish of plastic molded parts. A rougher but uniform finish of painted parts.

Visible Surface Surfaces those are visible when the enclosure or part is installed in a completed assembly.

Void The failure of ink to define a graphic feature.

Warpage Dimensional distortion in a part after molding, pressing or laminating. Twist or bows in the part.

Water Spots Rough and not densely packed dull gray lines at plated material.


Weld lines Line where molten plastic or metal joins form a part. A weld line usually appears as a noticeable line or gloss variation across the surface of the part.

3 Preferred Appearance Quality PAINT Preferred

o Painted surfaces should be defect free and the texture and color should be uniform throughout the entire surface.

o The finish on a continuous surface shall exhibit no gross imperfections such as gouges, large chips, runs, blisters, oil spots, flaking, or any defects that will affect the functional properties of the finish.

o Paint touch-up is acceptable. o A touch-up is not acceptable if visible at the viewing distance for that class of surface.

SILK-SCREENING Preferred

o Silk-screened logos or symbols should be defect free, and should withstand cleaning with mild solvents and the tape pull test.

PLATING Preferred

o Visible outside surfaces should be defect free, and die and slug marks should not be visible. CHEMICAL CONVERSION COATING (Alodine) Preferred

o The finish shall have uniform appearance; be semi-bright, smooth, and clear to slightly yellow or iridescent in color. Visual appearance will vary between different alloys and between machined, milled, cast, and grained surfaces.

o Outside surface shall be free from scratches, dents, or gouges. INSPECTION REQUIREMENTS Viewing Conditions

o The inspector shall scan the surface in a continuous manner. All judgments shall be made from the specified lighting, viewing distance, angle and material classes as described below.


4 Surface Categories Class A

o Is a critical cosmetic surface usually front exterior surface which is most often closely viewed by the user / customer

o Panels o Instrument cases o Desktop cases o Customer specified

Class B o Is a semi-critical cosmetic surface usually exterior surface which is adjacent to Class A, not

viewed as often but easily seen. Class C

o Is a non-critical cosmetic surface either exterior surface rarely viewed by the user / customer, such as back surface; or an internal surface that is visible but not normally viewed by the user / customer.

5 Light Source Light Specification

o White, cool artificial office lighting (e.g. fluorescent light) o Do not use direct sunlight.

Light Intensity o Uniform intensity between 70 and 120 foot-candles. (750 and 1250 Lux)

Caution: At levels of greater light intensity caution should be used to not over inspect the parts in order of accentuate surface flaws.

Light position

o Reflection free, non-directional from the top.

Caution: No direct overhead light above inspection table.


6 Inspection Table Surface The table surface should be made of a non-reflective dark color to avoid twilight conditions. Preferred: Black rubber mat Acceptable: Dark blue or dark green rubber mat Unacceptable: Light color table surfaces e.g. white, gray, yellow, metallic etc.

Caution: Reflective light-colored surfaces eliminate or accentuate surface flaws. 7 Viewing Time Class A

o Systems: Ten (10) seconds per 200 square inches per part o Front Panels: Five (5) seconds per 50 square inches per part

Class B o Seven (7) seconds per 200 square inches per part

Class C o Five (5) seconds per 200 square inches per part

8 Viewing Orientation During inspection, view objects in an orientation perpendicular to each surface. During assembly, view objects in normal orientation of manufacturing process. In some cases inspection should be held prior to assembly. Any visible surface flaw has to be verified against the acceptable defect matrix. Caution: Parts shall not be manipulated to reflect a single light source in order to accentuate surface flaws.

9 Magnification Tools Magnification tools may be used to find root causes for defects or to verify correctness of special areas. Caution: Magnification is not to be used when inspecting for cosmetic defects.

10 Viewing Distance Viewing Distances from the surface being inspected Class A

o 24 Inch (610 mm) Class B

o 30 Inch (760 mm) Class C

o 36 Inch (760 mm)


11 Acceptable Defects Matrix



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1 Purpose and Scope - Viasat